technology improving your meltshop performancefoundryinfo-india.org/images/pdf/3b1.pdf · the...
TRANSCRIPT
| 1 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
INTRODUCTION
Every casting (Fig.1) begins with molten metal and every
foundry wants to make a profit. To melt metal, it requires
energy and in the case of an induction furnace it means
kilowatts.
More efficiently one uses those kilowatts, lower is the
costs and the greater is the profit.
Fig. 1: Typical automotive castings.
There are “technologies” and practices out there designed
to help, and the basis of this paper is to give a better
understanding of what these are and how they can be
implemented in an iron foundry.
Once it is established about how much molten metal is
required per “batch” the frequency at which a “batch” is
required, in conjunction with the “utilisation” would
determine the kilowatts are required and the total
production would determine the quantity of power
supplies required.
The following are the stages one must go through to get a
ladle full of metal with a specific analysis at the required
temperature:
MELT CYCLE - is the period when maximum power is
continuously applied to the furnace and charge is added.
Technology Improving YourMeltshop Performance
NON-PRODUCTION CYCLE - is when no or reduced
power is being applied, such as when the initial charge is
being added, when slag is being removed, when a
temperature dip or analysis sample is being taken, waiting
for an analysis result and pouring the furnace empty.
PRODUCTION CYCLE - is the “melt cycle” and the
“non-productive cycle”.
UTILISATION - is the “melt cycle” divided by the
“production cycle” expressed as a percentage. If the
melting cycle is of 45 minutes and the “non-production”
cycle is of 45 minutes, then the “production cycle” is 90
minutes. The 45-minute “melt cycle” divided by the 90-
minute “production cycle” times 100 gives an “utilisation”
of 50%.
If it is a process that requires 10 tonnes of iron poured
into moulds per hour and the “production cycle” is such
that it can only achieve 50% “utilisation”, one will have
to buy a power supply capable of melting 20 tonnes per
hour.
CHARGE MATERIALS - for producing gray and
ductile iron, the charge consists of steel scrap, pig iron,
in-house returns and scrap.
CHARGE PREPARATION and CHARGING -
irrespective of whether the furnace is to be charged
manually or mechanically, the charge materials should
be weighed and these ought to fit into the furnace. If the
scrap sections are long and extend out of the top of the
furnace, these, will ultimately melt but will take time,
which will influence the “utilisation”. The initial charge
needs to be as quick as possible and of sufficient density
to allow maximum power. The initial charge needs to be
added to the furnace as quickly as possible. For optimum
performance, the density should not be less than 1,750
kg per cubic metre and the furnace must be filled to a
minimum of 30% and maximum of 60% of its rated
capacity.
Graham Cooper
| 2 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
SLAG REMOVAL - an essential but unpleasant job.
The slag produced during melting iron is usually viscous
and, if not, the addition of a pearlite-based coagulant will
create a viscous slag that can be raked or lifted off. For
any sized furnace removing the slag manually is possible,
but on larger furnaces it is unpleasant and time
consuming. The options for larger furnaces are “back tilt
slag removal” or a slag grab.
TEMPERATURE DIP AND SAMPLE ANALYSIS -
a temperature dip to establish the bath temperature and
a molten metal sample has to be taken to establish the
chemical composition.
CHEMISTRY ADJUSTMENT AND SUPER-
HEATING – as soon as the analysis result is known the
“trim” materials should be weighed and charged into the
furnace and full power applied to superheat to the pouring
temperature.
POURING CYCLE - the time taken to empty the
furnace.
To help one to achieve an optimum “production cycle”
one needs to understand fully the technologies and
practices that are available.
THE CHARGE - Every “melt cycle” starts with a charge
(Fig. 2). The charge materials must be weighed before
these are put into the furnace. When the charge is fully
molten it is easier to calculate any “trim” additions, if the
weight of the liquid iron is known.
If “standard” charges for various grades of iron are
developed, it is much easier to achieve the target analysis.
One will be able to use more lower cost materials, as one
will learn the addition and recovery rates for the various
materials used for element additions.
The quality of these materials and the charging sequence
are important. Rust on steel scrap can influence lining
life. Sand on in-house returns has to be melted and then
removed as slag. Purchased cast iron scrap may contain
unwanted elements and must be purchased with care. To
melt slag, energy required is twice as much as that for
iron.
Alloying materials also influence performance of the “melt
cycle”. As a base recarburiser, one can use a lower cost
petroleum coke (Fig. 3).
Fig. 3: Petroleum coke.
If this is for gray iron, materials with higher sulphur levels
can be used as final sulphur of 0.5 to 0.12%, enhances
the performance of ferro silicon-based inoculants. Silicon
addition should be made using 75% silicon ferrosilicon
as this is an exothermic reaction. An alternative source
of silicon is silicon carbide which is 66% Si, 33% C and
zero carbon and an important consideration if one is
making a ductile or compacted graphite iron.
At the end of the melt, it is often necessary to make small
adjustments to “trim” the final analysis.
The charging sequence will influence carbon pick-up. Pig
iron is high in carbon and the carbon is already in the
iron matrix. It should be charged late in the “melt cycle”.
In-house foundry returns and scrap are of known analysis
Fig. 2: Typical charge materials.
| 3 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
with the elements in the matrix so they can be added last.
Steel is low in carbon and carbon can enter the matrix.
The charging sequence should be steel scrap, recarburiser,
in-house returns and scrap, pig iron (if required) and ferro
alloys.
Any “trim” materials should be added after the slag has
been removed and the charge is being superheated.
The furnace should not be overfilled. Any molten metal
above the power coil at the end of the “melt cycle” reduces
the surface stirring and subsequent surface, when “trim”
materials are to be added. Movement caused by thermal
convection and carbon boil does not enhance element
recovery.
For any high production, a mechanised charging system
is essential. The initial step is to weigh the charge. A
crane scale can be used to weigh a charge as it is loaded
into a feeder. A furnace feeder can be mounted on a
track weighing station. A weigh hopper (Fig. 4) can be
positioned to discharge into a feeder.
Fig. 4: Feeder and weigh hopper.
The best option is to select a feeder that can hold a full
furnace charge. If it is a large furnace, then a feeder thatholds half the charge can be used but, in this case, a weighhopper also capable of holding half the charge is essentialto ensure no delays in the charging sequence that couldaffect the “utilisation”.
The size of the scrap is important to ensure the chargedoes not bridge. On average, each piece should not havea dimension greater than 33 % of the furnace diameterand no dimension should ever exceed 50% of the furnace
diameter. The feed rate of the system must be able to
deliver the full charge into the furnace within 65 to 70%
of the actual “melt cycle”.
The equipment must be sized based on the scrap density
available (Fig. 5). There is no point in buying a 5-tonne
feeder based on 2 tonnes per cubic metre, if the only scrap
available is 1 tonne per cubic metre or less.
Fig. 5: Typical scrap densities
Fig. 6: A possible charging system configuration.
The degree to which a charging system (Fig. 6) can be
mechanised is endless and depends on the degree of
automation required. Software to automate the system
is available from a number of suppliers (Fig.7). Different
materials can be stored in separate weigh hoppers. The
analysis of the various materials in the weigh hoppers can
be entered in the computer along with the formula of the
| 4 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
Fig. 7: Charge system computer screen.
grades of iron to be produced and the batch size. The
software will select a charge-based on the materials
available to ensure one get the maximum use of elements
already in the charge. Based on the feedback from a
spectrograph and the furnace load cells, the computer will
calculate the “trim” materials required. Once all the
necessary data has been loaded, a computer system will
generally provide the following information:
Weight and analysis of various materials in storage
weigh hoppers with maximum and minimum stock
levels.
Recovery rates for materials used.
Formulation for grades of iron to be produced.
The grade of iron currently being produced with
weights of the various charge materials required.
A report to a crane operator to indicate what
materials and weights are required.
The total weight of each charge.
Printed reports.
Weight of any trim material required.
The sequences in which multiple furnaces are to be
charged.
Information available from the computer system
can usually be accessed through the internet or a
LAN network.
When the weighed charge has been loaded on to the
furnace feeder, the feeder will index to a position behind
the furnace to be charged.
The only functions not automated are, indexing the feeder
forward over the furnace and starting the feeder. This is
for safety reasons to ensure the feeder is in the correct
position and the area is clear. As the melt progresses,
the operator needs to stop, and start the feeder to ensure
the furnace is always full but not overfilled.
Fig. 8: Melting at full power.
THE MELT CYCLE - the “melt cycle” starts as soon as
sufficient charge material is in the furnace to enable power
to be applied (Fig. 8). Modern power supplies
automatically control the power being applied to the
furnace as the condition in the furnace changes (Fig. 9).
The goal is to get the energy into the charge as quickly
and efficiently as possible. A power supply able to deliver
maximum power throughout the “melt cycle”, always
achieves the best melt rate. As the charge goes through
“Currie”, the voltage applied to the coil is allowed to
increase. This increase gives two advantages:
Fig. 9: Factors that will influence power usage.
Firstly, it ensures maximum kilowatts are continuously
applied to the coil. Secondly, a high coil voltage means
that the voltage induced into the charge is higher and
| 5 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
therefore the contact heating in the charge is more
efficient. Typically, this results in a ten percent
improvement in the melting rate as compared to a power
supply where the power draw drops as the charge passes
through “Currie”.
Fig.10: Melt cycle screen
Computer systems are available which will help manage
the “melt cycle” (Fig. 10). The final pouring temperature
is entered into the display. Taking a signal from the
furnace load cells and the kilowatts being applied to the
furnace, the computer’s algorithm displays a calculated
temperature as a vertical bar chart, which has set points
for various alarms and functions. As the display
temperature increases the operator is prompted to add
charge to the furnace. A temperature alarm is set at the
temperature the charge will be fully molten. This alarm
calls for a temperature dip. However, it is also the point
at which power should be turned off and the slag removed.
The computer system generally provides the following
functions and reports:
Manages an automated “melt cycle” (Fig. 10).
Starts the equipment at a predetermined time to
preheat the charge.
Provides an automatic sinter cycle (Fig. 11).
Provides diagnostics.
Displays a simulated bath temperature.
Displays information about the power supply.
Displays the weight of charge in the furnace.
Displays drain temperatures and alarms.
Maintains a record of alarm trips.
Provides printed reports.
Communicates via the internet or a LAN network.
Fig. 11: Sinter cycle screen
SLAG REMOVAL - During the removal of any slag, the
power must be off to ensure all the slag floats to the
surface and can be removed. The longer the power is off
the greater the effect on the overall “Utilisation”.
Manual removal can be enhanced by using a pearlite-
based slag coagulant, which will exfoliate to tie the slag
pieces together so they can be lifted off. Howeve,r it is a
hard and unpleasant job.
Fig. 12: Back slag removal.
If the furnace is larger, a back slag (Fig. 12) feature may
be available. In this case, the furnace is constructed with
| 6 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
two stanchions, which allow it to tilt in two directions,
and there is a second spout at the back opposite to the
pouring spout. When required, the furnace is back tilted
and the slag is raked into a slag bugging positioned under
the rear spout. The advantage of this system is that the
operator has to rake rather than lift, and the process can
be completed much quicker but there is a cost involved
at the time of purchase.
Another option is to use a slag grab (Fig. 13). This is a
pneumatically powered unit, which is suspended from a
crane or hoist above the furnace. It comprises of two
replaceable steel plate jaws that are opened and closed
by a pneumatic cylinder. With the jaws open the unit is
lowered into the slag, the jaws are closed and lifted out of
the furnace. It is then swung to the side and the jaws are
opened to drop the slag.
Fig. 13: A slag grab.
Fig.14: A mechanized slag grab.
A variation of the slag grab is a powered unit, which is
mounted on a structural steel frame that forms part of
the melter’s cabin between the furnaces (Fig. 14). The
unit can be swung to either side of the cabin to service
two furnaces. The jaw assembly is moved up and down
by a power cylinder and the action of the jaws is the same
as the crane mounted unit. This type of unit is useful if
the slag has a strong crust that needs a force to break
through the slag surface.
The key is to remove the slag as quickly and efficiently as
possible.
Fig. 15: Carbon, silicon and CE unit
TEMPERATURE DIP AND SAMPLE ANALYSIS -
in most iron foundries, a thermal analysis system is used
and the metal is poured based on the resulting carbon
equivalent reading and a carbon percentage (Fig. 15). If
a spectrograph analysis result is required then there will
be a delay, which adversely affects the untilisation.
Just after the temperature dip (Fig. 16) and analysis
sample are taken, holding power is restored to the
furnace.
Fig. 16: Dip temperature unit.
CHEMISTRY ADJUSTMENT AND SUPERHE-
ATING - depending on which analysis system is used,
| 7 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
just as the result is known, the “trim” materials should
be weighed and charged into the furnace.
If a spectrograph is to be used, the positioning of the unit
and the means by which a sample is delivered to the
laboratory and the result transmitted to the furnace
operator needs to be carefully thought out to ensure it
can be accomplished in the shortest possible time.
The carburiser used to “trim” needs to be small-grained
(Fig. 17) to increase its surface area and full-graphitised
as this ensures that it goes into solution quickly. The
function of carbon entering the iron matrix requires time,
temperature and a large contact surface. If a large-grained
petroleum coke is used at this point it will take longer to
enter the matrix and adversely affect the “utilisation”.
Silicon additions should be made using a crushed 75% Si
material.
Fig. 17 : Correctly sized “trim” graphite.
Immediately after the “trim” materials are in the furnace
full power should be able to superheat the charge and
create surface movement to increase the contact area. The
rate at which a given furnace capacity and power supply
will always superheat can be established, during the
commissioning. When the required degree of superheat
has been established, maximum power can be applied for
the required time and further temperature dip is not
necessary.
If the “melt cycle” is being managed by a computer a
mouse click will restart the power supply and the
computer will control the power to ensure only the
required amount of energy has been applied. At the
conclusion, an alarm will signal to alert the operator and
the power will be reduced to holding power.
ROBOTICS - software which allow a robot to carry out
a number of the these functions include:
Slag removal by raking or slag grab (Fig. 18)
·Temperature dip
Taking a liquid sample and pouring it into a thermal
analysis cup or chill mould
Adding pre weighed “trim” materials.
Fig. 18: A robot being used to remove slag.
The robot’s advantage is that it cannot be hurt, it does
not take rest breaks or holidays and it performs the same
way every time.
POURING - at the conclusion of the superheating/trim
addition cycle the furnace is ready to be poured empty.
If it is wanted to get the maximum advantage of the
contact heating as the charge goes through Currie one
must pour the furnace empty.
Very simply, the faster the furnace is emptied the better
(Fig. 19). During the pouring cycle, only low power is
applied and the time it takes to empty the furnace has
the greatest effect on the “utilisation”.
SUMMARY – If it is desired to purchase a specific
amount of energy from the utility supplier and biggest
profit is planned.
The one factor that will have the most effect is the level
of “utilisation” that can be achieved. Higher “utilisation”
| 8 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
is better. High utilisation means energy efficient
production cycles.
Fig. 20: A simple Power-Trak circuit.
EXAMPLE 1 - A 12,000 kW Power-Trak working with
a 17.5-tonne furnace with a hot lining and an empty
furnace will melt iron to 1,550oC at a rate of 25.2 tonnes
per hour at 100% “utilisation” +/-5% (Figs. 20 & 21).
It will melt 17.5 tonnes to 1,450oC in 39 minutes +/-5%.
A 12,000 kW will superheat 17.5 tonnes of iron through
100oC in 3 minutes +/-5%.
The 17.5-tonne furnace with a silica lining holding iron
at 1,550oC will require 250 kW per hour to overcome the
thermal losses +/-5%.
The following are two charts listing the operations
required for a full melt cycle (Fig. 22). In both cases, the
kilowatts and furnace size is the same. The time required
to melt and to superheat is the same in both.
Fig. 19 : A large capacity crane mounted ladle. Fig. 21: A typical melt and pour cycle for a Power-Trak
delivering batches to the casting plant.
Fig. 22 : Utilisation.
| 9 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
However, in the right-hand chart, (Fig.22) the time taken
for various operations is longer.
The calculation at the bottom shows the effect the
“utilisation” has on the production rate.
In both cases, one has to purchase a 12,000 kW supply
from the utility company. Yet only 40 - 50% of the total
production capacity can be achieved.
Fig. 23: A simple Dual-Trak circuit.
EXAMPLE 2 - A 12,500 kW Dual-Trak Plus has two
12,000 kW inverters (Fig. 23) working with two 17.5-
tonne furnaces and each of these will provide the same
performance as a single 12,000 kW Power-Trak. The extra
Fig. 24: Typical melt and pour sequence for a Dual-Trak delivering a
constant supply of metal to the casting plant.
500 kW in the AC/DC sections allows the unit to
simultaneously provide upto 500 kW to a second furnace
to maintain temperature.
Each furnace will melt and pour in sequence (Fig. 24). If
the “melt cycle” and the “non productive cycle” are equal
in duration, then you will achieve close to 100%
utilisation.
In practice, the utilisation of a Dual-Trak © power supply
is between 85 and 95% and there is a constant supply of
metal to the foundry casting process.
EXAMPLE 3 -A Tri-Trak has three inverters each rated
at 100% kW and three furnaces (Figs. 25 & Fig. 26). The
AC/DC section is rated at 210% of an inverter.
Each furnace will melt and pour in sequence. In this
case, to achieve 100% utilisation the “non-productive
cycle” must not exceed 50% of the “melt cycle” (Fig. 27).
THE MESSAGE: There is technology out there in
practice, materials, hardware and software that will
enable to run the equipment more efficiently. The more
efficiently one runs the equipment the higher will be the
| 10 |
TRANSACTIONS OF 61st INDIAN FOUNDRY CONGRESS 2013
“utilisation” of the equipment, and the KVA power supply
purchased from the utility company.
However, to achieve this, one will need properly trained
personnel and a management structure that ensures
training is kept upto date and the equipment is properly
and timely maintained.
Fig. 25: A simple Tri-Trak circuit.
Fig. 26 : Tri-Trak installation.
Fig. 27 : A typical melt and pour sequence for a Tri-Trak
delivering constant supply of metal to the casting plant.